Luiz Maurcio V. Tigrinho et al.

Luiz Maurcio V. Tigrinho

tigrinho@ensitec.com.br

Ricardo Adriano dos Santos

ricardo@portalmecanica.com.br

Ravilson Antonio Chemin Filho

ravilson@pop.com.br

Paulo Victor P. Marcondes

marcondes@ufpr.br
Universidade Federal do Paran - UFPR
Caixa Postal 19011
81531-990 Curitiba, Paran, Brazil

Experimental Investigation on the

Influence of the Lubricant Type in the
Punch Stretching of Extra DeepDrawing Steel
In sheet metal stamping, several variables must be taken into account such as the
materials mechanical properties, the tools geometry, interface lubrication between punch
and sheet metal and deformation rate, among others. This paper reports on a study of the
lubricants influence on the stretching forming process. The lubricants used ranged from
liquid, such as mineral and vegetable oils with extreme pressure additives and synthetic
fluids to solid PVC (polyvinyl chloride) and polyurethane films. In this work, the main
objective was to study a minor strain profile as an alternative method to analyze the
influence of solid and liquid lubricants on stretching forming of high stampability steels
(DC 06). The minor true strain distribution profile was obtained, from the die radius to the
punch pole, from stamping tests with stretching characteristics. Analyses of the strain
distribution profile and of the fracture position allow an evaluation of the lubrication
efficiency. Of the five lubricants studied, the results indicated that the solid polyurethane
film yielded the best performance, promoting a more homogeneous distribution profile of
the minor true strain (2), increasing from the die radius to the punch pole, where tearing
of the metal sheet occurred.
Keywords: hemispherical punch-stretching, lubrication and extra deep-drawing steel

Introduction
1

Stamping is a process used in the manufacture of parts from

sheet metal. Among the major users of this process are the
automotive and home appliance industries, which seek to increase
their competitiveness by reducing manufacturing time and cost
(Klocke and Mamann, 2005).
The evaluation of whether or not a sheet metal can be formed
without defects depends on the materials properties, surface
conditions, size and shape of the blank, lubrication, press speed,
pressure applied by the punch and the die and punch design
(Kuzman, 2000) and (Brown and Bosler Jr., 2006).
According to Keeler (2000), when a sample tears or shows
excessive thinning, more lubricant is often added in an attempt to
solve the problem. However, this is not always the best solution and
the lubrication is still little studied and poorly understood (Keeler,
2001).
Lubrication of the punch does not affect deep drawing to any
significant extent as if does in stretching deformation mode. For the
stretching condition the punch must be well lubricated so that the
strains can be prolonged to higher deformation levels (Keeler,
1968). Besides, subtle differences in the stamping process, i.e., die
design and metallurgy of the piece, can strongly affect the lubricant
performance (Kren, 2003).
In the flange region, in stretching forming, or more precisely, in
the draw bead the friction should be as high as possible so that the
flow of the sheet into the die is rendered difficult and thus
increasing sheet tension. The same holds true for the die radius.
However, friction should be as low as possible in the punch radius;
there should be a relative movement between the punch surfaces and
the sheet metal, which is being formed at the thickness reduction
expense. The opposite occurs in deep drawing mode. In this forming
situation the material needs to flow into the die cavity. For this
reason, in the flange and on the die radius regions, the friction
should be as low as possible to enable the material to flow freely.
However, the same thing should not occur on the punch radius,

where friction should be at its maximum so that no relative

movement occurs between the surfaces. This is important to prevent
the material from tearing prematurely reaching a high deformation
level.
The stamping success, in terms of part integrity and surface
quality, is strongly dependent on the tribological behavior during the
process. This behavior is a result of a complex set of factors such as
tools design, blankholder force, surface quality and topography of
both tools and sheet materials, and also of the lubricant properties
(Carcel et al., 2004).
Recently, Tigrinho, (2005) demonstrates the FLC (Forming
Limit Curve) for the DC06 steel obtained without lubrication and
the extension of the minor true strain curve for 200x200mm
specimen obtained with the application of polyurethane as lubricant,
Figs. 1a and b. Using this lubricant, points with a higher minor true
strain (2) were generated, with values of about 0.48, while the true
strain level reached only 0.11 without lubrication. These results
indicate a real gain of 37% in the materials forming ability in
stretching forming (using polyurethane).
In this work, a minor true strain profile was proposed as an
alternative method to analyze the influence of solid and liquid
lubricants on stretching forming of DC 06 high stampability steel.

Experimental Procedure
The material used was a cold-rolled mild steel (0.7mm
thickness) produced by Thyssen Krupp to the DC06 specification
(EN 10152, 1993). This material was selected for the laboratory
tests, because it is a high stampability material, i.e. hardening
coefficient (n) of 0.26 and anisotropy coefficient (r) of 2.26. The
material showed 1=0.81 and 2=-0.48 on deep drawing state,
1=0.44 and 2=0 on plane strain state and 1=0.53 and 2=0.48 on
stretching state (Tigrinho, 2005). The larger the n and r coefficients
the better will be the material stampability (Kumar, 2002).

Paper accepted August, 2008. Technical Editor: Anselmo Eduardo Diniz.

290/ Vol. XXX, No. 4, October-December 2008

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Experimental Investigation on the Influence of the Lubricant Type in the

FORMING LIMIT DIAGRAM

0,9
0,8
0,7
Major Strain 1

0,6
0,5
0,4
0,3
0,2
0,1
0
-0,6

-0,5

-0,4

-0,3

-0,2

-0,1

0,1

0,2

0,3

0,4

0,5

0,6

0,4

0,5

0,6

Minor Strain 2
FLD w ithout lubrication

Strain w ith Polyurethane

(a)

FORMING LIMIT DIAGRAM

0,9
0,8
0,7

Major Strain 1

0,6
0,5
0,4
0,3
0,2
0,1
0
-0,6

-0,5

-0,4

-0,3

-0,2

-0,1

0,1

0,2

0,3

data from the stretching forming when the samples width suffices
for the full action of the draw bead around the entire stamped cup
to plane state deformation, and to negative minor strain when the
sheet is narrower, so that a lateral portion of the test specimens is
not held down by the draw bead. In this study, the tests were carried
out only with 200x200mm test specimens, which were used with
and without lubrication, to simulate mainly the stretching condition,
since lubrication has no significant influence on deep drawing as in
stretching mode (Keeler, 1968).
In order to measure the minor true strain (2) a 4.2mm diameter
circular grid was printed on the test specimens surface. The grid
was printed using a process developed in the Forming Laboratory
(LABCONF) of the Federal University of Paran (Tigrinho, 2004).
This process differs from the processes used previously (electrolytic
marking, photo-sensitive resin or laser). This marking process uses a
screen (mask), similar to the screens used in silkscreen process, and
a grid fixer developed for the coated metallic sheet employed. This
process proved to be simpler, easier to apply and cheaper. It requires
no special equipment for the grid printing process.
In the stamping process the test specimens, with the uniformly
printed circular grid, were deformed up to the moment of rupture.
The major and minor strains can be determined with precision,
leading to identification of each deformation zone, and eventually to
methods for preventing stamping defects (Xu, 2007). After the tests,
measurements were taken of the 2 deformation axes of the circles
positioned along a straight line, from the border of the stamped body
(die radius support site) up to the center of the body (punch pole
action site), Fig. 2. The measurements were taken on the side of the
test specimen opposite to the fracture in order to avoid
measurements in cracked circles (Moreira et al., 2003). An average
of three test specimens was evaluated for each test and the results
were recorded as a mean value (three measurements).

Minor Strain 2
FLD (w hithout lubrication and w ith polyurethane)

(b)
Figure 1. The DC06 steel forming limit diagram (a) comparison of the
forming limit curve obtained without punch lubrication and the points of
maximum attained strain (2) using polyurethane lubricant and (b) final
forming limit curve without lubrication and the 200x200mm test specimen
with polyurethane.

A total of five liquid and solid lubricants were used, classified as

water-emulsive, synthetic oils and solid films (Brown 2006, Klann
2000 and Trivett et al. 2004):
Polyurethane solid lubricant, 0.50mm layer thickness;
PVC (polyvinyl chloride) film solid lubricant, 0.05mm layer
thickness;
Mineral oil + vegetable oil emulsive (1:2), with extreme
pressure (EP) additives, viscosity at 40C of 30cSt and density
at 20C of 0.880g/cm3;
Synthetic fluid prelube (used as anticorrosive after rolling),
biodegradable, easy removal, viscosity at 40C of 35cSt and
density at 20C of 0.880g/cm3;
Synthetic fluid emulsive (1:2), easy removal, viscosity at
40C of 17cSt and density at 20C of 0.880g/cm3.
After application of the polyurethane on the sheet metal surface,
a 3-hour wait for curing should be observed while the resin mixes
with its catalyzer.
The forming limit test (at fracture) was carried out using a
50mm radius hemispherical punch and a 10mm radius die (106mm
internal diameter). Originally, this test includes a total of 18 test
specimens, all of them 200mm long, but with widths varying from
40mm to 200mm (Nakazima et al., 1968). This variation in the
width of the test specimens is the determining factor for providing
J. of the Braz. Soc. of Mech. Sci. & Eng.

Figure 2. Test specimen illustrating the position of measured points, from

the die radius to the punch pole.

The results were compiled on a graph that shows the variation of

the minor true strain, from point 1, corresponding to the die radius,
to point 12, corresponding to the punch pole. As we analyzed a
simple shape part the forming limit strain diagram was chosen
instead the forming limit stress diagram independently on strain
path (Gronostajski et al., 2004).

Results and Discussion

With the forming tests a qualitative and quantitative analyses
can be made to determine the lubricants effectiveness. As a general
rule the better the lubrication less thinning occurs (Kim et al., 2007).
In the tests with the five lubricants plus the test without punch
lubrication, using the 200x200mm test proof, the rupture

Copyright 2008 by ABCM

October-December 2008, Vol. XXX, No. 4 / 291

Luiz Maurcio V. Tigrinho et al.

consistently occurred between the die radius and the punch pole.
The location of the fracture can determine homogeneous
deformation or if deformation peaks were generated. This can
indicate whether the lubrication system was efficient or inefficient.
Figure 3 shows the minor true strain distribution profile of the
200x200mm test specimen tested with and without lubrication.

Deformations distribution profile

Prelube synthetic fluid

0,35

mean value

0,3

Major strain

0,25

Deformations distribution profile

Without lubrication
0,35

mean value

0,1
0,05

0,3

Major strain

0,2
0,15

0,25

-0,05

0,2

10

11

12

Distance of die radius to the punch pole

0,15

Prelube synthetic fluid

0,1

(d)
0,05
0
1

10

11

Deformations distribution profile

12

PVC film

Distance of die radius to the punch pole

0,35

Without lubrication

0,3

mean value

0,25

Major strain

(a)

Deformations distribution profile

Oil EP

Major strain

0,35

mean value

0,2
0,15
0,1

0,3

0,05

0,25

0
1

10

11

12

-0,05

0,2

Distance of die radius to the punch pole

0,15

PVC film

0,1

(e)

0,05
0
1

10

11

Deformations distribution profile

12

Distance of die radius to the punch pole

Polyurethane film

0,55

mean value

0,5

Oil EP

0,45

Major strain

(b)

Deformations distribution profile

Emulsive synthetic fluid

0,35

0,4
0,35
0,3
0,25
0,2
0,15

mean value

0,1

0,3

Major strain

0,05
0,25

0
1

0,2

10

11

12

Distance of die radius to the punch pole

0,15

Polyurethane film

0,1

(f)

0,05
0
1

10

Distance of die radius to the punch pole

Emulsive synthetic fluid

11

12

Figure 3. Minor true strain profile from the die radius to the punch pole: (a)
without lubricant (b) with a combination of mineral and vegetable oils with
extreme pressure additives (c) with emulsive synthetic fluid (d) with
prelube synthetic fluid (e) with solid PVC film and (f) with solid
polyurethane film.

(c)

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Experimental Investigation on the Influence of the Lubricant Type in the

The curve shown in Fig. 3a, without lubrication, shows a minor

true strain peak (2) of 0.32 at point 5 i.e., both the rupture and the
strain peak occurred away from the pole, characterizing a
heterogeneous deformation. The rupture occurs along the pole, with
a minor true strain peaks formation, when inadequate lubrication is
used in the stretching condition.
The deformation distribution profiles depicted in Figs. 3b, c, d
and e, correspond to the stamped samples with a combination of
mineral and vegetable oils with EP additives, emulsive synthetic
fluid, prelube synthetic fluid, and solid PVC film, respectively.
These figures consistently show a maximum minor true strain peak
(2) at point 5, similar to that produced without lubrication (Fig. 3a).
For all cases both the rupture and the minor true strain peak
occurred away from the punch pole. This is characteristic of
inexistent lubrication condition and an inadequate condition for the
stretching forming mode. This mode requires good lubrication and
the smallest possible friction at the punch/sheet metal interface
allowing for a more homogeneous deformation profile.
With mineral and vegetable oil with EP and emulsive synthetic
fluid, Figs. 3b and c, respectively, it could be noted that although the
minor true strain peaks are concentrated at point 5, they were less
marked than those produced with prelube synthetic fluid and PCV
film, Figs. 3d and e, respectively. These cases displayed a much
more marked deformation profile at their minor true strain point (2)
indicating that, even though their minor true strain peaks occurred at
the same point, the mineral and vegetable EP oil and emulsive
synthetic fluid were more effective than the prelube synthetic fluid
and the PVC film in stretching condition.
The curve showed in Fig. 3f, obtained with the use of
polyurethane film, shows the minor true strain (2) increasing from
0.03 at the die radius to a maximum of 0.48 at the punch pole. This
characterizes a more homogeneous condition without minor true
strain peaks away from the punch pole, indicating that the
lubrication was efficient i.e. contributing to a more uniform
deformation profile.
This more homogeneous deformation profile will result in
stretched formed products with lower residual stresses and,
therefore, tending to make better use of the material formability.
Studies had demonstrated the effect of the lubricant on the
materials conformability (Jeffery, 2003). In deep drawing process of
aluminum sheet the solid lubricant promoted an increase of 40 to
50% in the materials conformability compared with the performance
of the liquid lubricants. Another good performance was in the
forming of a steel plate of high resistance, which solid lubricant
allowed the material stretching from 26 to 32% compared with the
liquid lubricants.
Experimental tests in the stamping of 5000 back covers of the
Dodge Dakota using solid lubricant reduced the amount of parts
with defects for less than 1%. The same part showed 40% of
defective peaces using oil based lubricant, (Jeffery, 2003).
It could be also noted that with good lubrication the minor true
strain (2=0.48) approaches of the major true strain (1=0.53)
characterizing a pure biaxial stress state. An important fact to be
considered is that the polyurethane film remained continuous,
without tearing, even after stamping (Fig. 4a and b).
With good lubrication in the stretching forming tearing tends to
occur close to the pole with high values for the minor true strain
(2), very often close to the major true strain (1) (Hosford, 1993).
The homogeneous minor true strain profile attained, with DC06
steel sheet, using the polyurethane film is due to the film efficiency
that separates the sheet metal surface from the punch surface,
preventing them from coming into contact, thus reducing friction
and providing a more homogeneous deformation. In this case, it is
unnecessary to shear the surface between the sheet and the punch.
As the sheet metal is deformed by the punch, the polyurethane
J. of the Braz. Soc. of Mech. Sci. & Eng.

deforms, allowing relative movement between the surfaces without

the need for shearing, rendering a more homogeneous deformation.
With the polyurethane film the rupture occurred very close to the
punch pole.

(a)

(b)
Figure 4. Formed sample: (a) continuous polyurethane film even after
forming (devoid of tearing) and (b) top view of the failed sample.

Conclusion
During forming processes, lubricants typically applied along the
tool-workpiece interface increases sheet formability. These
lubricants allow contact pressures to be more evenly distributed and
improve the surface quality of the formed parts. When the solid
polyurethane film was used, the minor true strain distribution profile
(2) was more homogeneous, starting from a low deformation level
close to the die radius and increasing to a maximum value exactly at
the punch pole, where rupture occurred. It was in agreement with
Hosford (1993) and with this solid lubricant that the biggest minor
true strain was achieved. The fracture at the punch pole confirmed
the efficiency of solid polyurethane film for stretching forming. An
analysis of the polyurethane film also indicated that it remained
continuous and unbroken, even after stamping, proving that the film
effectively kept separate the punch and the sheet metal surfaces. A
more homogeneous deformation will result in formed products with
lower residual stresses. The liquid lubricants and the solid PVC film
did not show the same performance as the polyurethane film. In this
case, both the fracture and the minor true strain peak occurred away
from the punch pole. In these cases the lubricant film must have
broken down, as the pressure increased during forming, exposing
the contact between punch and the sheet metal surfaces resulting in
the premature rupture.

Copyright 2008 by ABCM

October-December 2008, Vol. XXX, No. 4 / 293

Luiz Maurcio V. Tigrinho et al.

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